Hydrogen-Swellable Elastomer Fillers for Wellbore Isolation

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Solution Overview

Problem

Existing sealing materials designed to swell in the presence of fluids like water and hydrocarbons are not suitable for hydrogen due to high hardness and reinforcing filler content, limiting their applicability in hydrogen storage and transport applications.

Innovation Solution

Development of hydrogen swellable materials comprising elastomers with a hardness between 40 shore A and 80 shore A that swell by 40% to 100% in the presence of hydrogen, utilizing fillers such as carbon black, minerals, and metals that form metal hydrides to enhance hydrogen absorption.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional sealing materials with high reinforcing filler content are used, then structural strength is improved, but hydrogen compatibility and swelling capability deteriorate

Engineering Contradiction:

Improvestructural strengthVSAvoidhydrogen compatibility

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent changes the chemical composition parameters of the sealing material by incorporating metal hydride-forming particles (such as lanthanum, cerium, or magnesium compounds) that can absorb hydrogen and form metal hydrides. This chemical parameter change enables the material to swell in response to hydrogen exposure while maintaining structural integrity through the balanced formulation of elastomer matrix and filler content

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite sealing material combining elastomer base material with metal hydride-forming particles and controlled reinforcing fillers. This composite structure allows the material to exhibit both the structural strength needed for wellbore sealing and the hydrogen-reactive swelling capability, as the metal hydride particles provide hydrogen absorption while the elastomer matrix provides flexibility and sealing properties

Inventive Principle:

Principle #40Composite materials

2Strength

If elastomer hardness is increased to improve sealing pressure resistance, then sealing durability is improved, but swelling responsiveness to hydrogen deteriorates

Engineering Contradiction:

Improvesealing pressure resistanceVSAvoidswelling responsiveness

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The patent optimizes the hardness parameter of the elastomer to a specific range (Shore A 40-80) that balances sealing pressure resistance with hydrogen swelling responsiveness. Within this parameter range, the elastomer maintains sufficient structural strength to resist wellbore pressures while remaining soft enough to swell effectively upon hydrogen exposure, achieving both sealing durability and adaptive swelling capability

Inventive Principle:

Principle #35Parameter changes

3Strength

If reinforcing filler content is increased to improve material strength, then mechanical durability is improved, but hydrogen absorption capability deteriorates

Engineering Contradiction:

Improvemechanical durabilityVSAvoidhydrogen absorption capability

Core Design Contradiction:

StrengthVSQuantity of substance

Solution Approach 1:

The patent formulates a composite material where metal hydride-forming particles replace traditional reinforcing fillers like carbon black or silica. These metal-containing particles (lanthanum, cerium, magnesium compounds) serve dual functions: they provide structural reinforcement similar to conventional fillers while simultaneously offering hydrogen absorption capability through metal hydride formation, thus maintaining mechanical durability while enabling hydrogen reactivity

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent makes the filler material multi-functional by selecting metal compounds that can both reinforce the elastomer matrix mechanically and absorb hydrogen chemically. The metal hydride-forming particles perform multiple functions: structural reinforcement, hydrogen absorption, and swelling actuation, eliminating the need for separate reinforcing fillers and hydrogen-reactive components

Inventive Principle:

Principle #6Universality (Multi-functionality)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The materials provide effective sealing and zone isolation in wellbores, enabling long-term compatibility with hydrogen and facilitating hydrogen storage and transport by swelling reversibly or irreversibly in response to hydrogen exposure.

Implementation Method 1

The sealing material swells in response to exposure to a hydrocarbon fluid or to exposure to water in the well

Methodology Applied

Scientific EffectDiffusion: Diffusion

Implementation Method 2

utilizing fillers such as carbon black, minerals, and metals that form metal hydrides to enhance hydrogen absorption

Methodology Applied

Scientific EffectHydride formation: Hydrogenation

Data Source

PatentUS20260042951A1Hydrogen swellable fillers for surface and underground fluid isolation barriers

Publication Date: 2026.02.12 SCHLUMBERGER TECH CORP

AI summary

The present disclosure relates to hydrogen swellable fillers, methods for their preparation and their use in, for example, oil-field exploration, production, testing, underground gas storage, production and transportation. The hydrogen swellable material can include an elastomer and a filler. The elastomer can have a hardness between about 40 and about 80 shore A, and the hydrogen swellable material swells in volume between about 40% and about 100% upon contact with hydrogen.